- the next assembly to come off is the main
spring assembly. Its made up of a spring, a small bushing,
and a silcone-rubber sleeve. This can be tough to get off in one
piece, as the silicone sleeve tends to freeze itself to the
center conductor insulator. Carefully twist and rock and pry to
free up the silicone sleeve, then slide it off of the old wire.

- CAUTION!!! This next step can be a real
finger biter. The only remaining parts to be removed are the two
pieces which make up last metal flange. They are pressed together
in a fashion which crimps the shield (braid) of the spark plug
wire. The fit is tight and to remove it you need to slide the
blade of a knife in and separate the two halves. Try a little bit
on one side, then the other, working back and forth until the
piece pops apart. KEEP YOUR FINGERS CLEAR!

That covers the connector disassembly. Save all
of the parts, as youll need them for the new wires.

Prepare the new 7mm wire:

- carefully strip 2 inches (~51mm) of outer (black)
insulation from the new 7mm spark plug wire. Do not allow the
inner insulation (white) to be damaged.

- strip ½ inch (~13mm) of inner insulation
from the center conductor.

Assemble old components onto new wire:

- assemble the two piece metal flange and slide
it onto the new wire. The black insulation will stop the flange
from sliding down the wire.

- install the main spring, flange, and silicone
sleeve.

- install the plastic sleeve onto the remaining
inner insulation and center conductor. You may need to twist the
wires which make up the center conductor to allow them to pass
through the plastic sleeve.

- pull the entire assembly back against the
black outer insulation. It will only move if you allowed any
components to slide back off of the wire. The object is to keep
the components together and tight where the two-piece flange is
resting against the outer insulation.

- you will now have about ¼" of center
conductor protruding from the plastic sleeve. Using a small pair
of diagonal cutters, clip the center conductor flush with the end
of the sleeve (NOT the spring.) Be CAREFUL to not clip the tiny
spring at the end of the plastic sleeve!

- install the brass brad into the plastic
sleeve, as it was installed in the original wire. This will hold
the assembly together, but it is somewhat fragile until installed
in the distributor cap.

OPTIONAL: If you wish to "glue"
the plastic sleeve onto the inner conductor (before sliding the
brass brad into place) you may do so with clear 100% silicone.
This will keep the center conductor in place when handling the
wires alone. Apply a small amount to the inner insulator. Do NOT
get any on the center conductor. If you choose this option, allow
at least 24 hours for the silicone to cure. Do NOT disturb the
wire while silicone cures.

- cut two pieces of 3/8" heat shrink
tubing for each end you are assembling. Cut one piece 1-1/2"
(~38mm) long and another piece 1" (~25mm) long.

- refer to Fig. 3 to see the new wire with
assembled components and the heat shrink tubing  ready to
be installed.

- slide the 1" piece of heat shrink tubing
onto the wire and locate it tight with the flange. Apply heat
from a heat gun (preferred,) lighter, or hair dryer to shrink the
tubing into place. Repeat this step for the 1-1/2" piece of
tubing. This piece will cover the first piece you installed.

- slide the lock nut (which screws to the
distributor cap) onto the wire. The distributor end is now
complete! (See Fig. 4)

Complete the spark plug wire assembly:

- cut the wire to proper length and install the
NAPA components as per their instructions.

- see the completed assembly below:

- to fabricate a new coil wire, simply assemble
the original pieces on both ends of the new wire.